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I recently purchased a '92 xlt bronco about 2 months ago. There were a few problems with it that I have been fixing to get it ready as a daily driver. When I purchased it the passenger window was slipping. A new set of bushings and gears fixed that in no time flat. Shortly after the driver side window stopped working, so I pulled that out and replaced the bushings also. Two of the bushings were shot, but one was still good. After reinstalling the motor and testing it, the window went up and down fine. I put the door panel back on and rolled it all the way up, but it would not come down. Loosened up the motor to disengage the gears, slid the window down and reattached the motor. Rolled it all the way up and the window sticks again. I greased the window channel and pulled everything apart and put it back together again a few times with the same results. It seems as if it is binding somewhere, but I cannot tell where. If one of the gurus on here could give me some advise I would greatly appreciate it.
It sounds like something is not lining up from the reassambly, and after the door panel is put back on. The fact that it worked fine until you put the door panel on points to this. Do you have any screws holding your door panel on? Many people (myself included) have added screws to hold the door panels on, to help with the typical door panel rattles that occur on Broncos. After a while those plastic clips just don't hold it tight enough, or they are broken after the door panel is removed, and people add screws. Anyway, if you have any non-factory screws holding the door panel on, see that they are not hitting something inside.
After reattaching everything the first time, I left the door panel off while I was trouble shooting it. I've been messing with it for the the past week off and on and have not been able to figure out the problem. If I can't figure out the problem tonight, I will pull the window motor winding from the passenger side and and make sure it is not a weak motor. With the motor pulled, I can't stop it from turning with my hand, so I don't believe that this is the problem, but will check anyways. Is there anything else that I should be checking, or possible binding spots I should be looking at? Any replies will be appreciated.
Might be a silly question but have you checked the switch. I had problem with the passenger side window. It would roll down but not up. I checked fuses, connections. Checked the switch and it turned out to be bad. I went really quick. One minute working the next minute it was bad. The switch has two contacts, one to go up the other to go down. The down worked but the up did not.
Just to clarify: you're saying that WITHOUT the door panel installed, you have NO trouble out of it either going up or down. Right? But when you install the panel, it won't go down at all. Right?
With panel installed, the engine off, and the door open, do you see the dome light get dim when you try to roll it down?